Insulated Shipping Container

Abstract

An insulating container is disclosed. The insulating shipping container includes an outer container and pieces of laminated foam, which are cut or scored to create hinges that permit the laminated foam pieces to be configured into an insulating enclosure. Alternatively, the laminated foam pieces may be formed without hinges and friction fit into the outer container.

1 . An insulated container comprising:
 an outer container; and   a plurality of laminated foam pieces,
 the laminated foam pieces each having a foam core with a first laminated face covering a side thereof; 
 the laminated foam pieces having at least one hinge created by a score in the foam core that does not extend through the first laminated face; and 
 wherein the laminated foam pieces are folded at the at least one hinge so as to create an insulating enclosure, the insulating enclosure positioned within the outer container. 
   
     
     
         2 . The insulated container of  claim 1  further comprising a second laminated face covering a side of the foam core opposite of that covered by the first laminated face. 
     
     
         3 . The insulated container of  claim 1  wherein the foam core is a graphite impregnated expanded polystyrene. 
     
     
         4 . The insulated container of  claim 2  wherein the first laminated face and the second laminated face are made from different materials. 
     
     
         5 . The insulated container of  claim 4  wherein the first laminated face is made from a material with a melting point higher than that of the second laminated face. 
     
     
         6 . The insulated container of  claim 4  wherein the first laminated face is made from polypropylene and the second laminated face is made from polyester. 
     
     
         7 . A method of assembling an insulated container comprising the steps:
 selecting an outer container;   selecting a first laminated foam piece and a second laminated foam piece;   folding the first laminated foam piece along a hinge;   placing the partially folded first laminated foam piece into the outer container;   folding the second laminated foam piece along two hinges;   placing the folded second laminated foam piece into the outer container; and   folding the first laminated foam piece along a hinge.   
     
     
         8 . A method of manufacturing an insulating enclosure comprising the steps:
 preparing a foam core by shaping it to a desired thickness;   joining two laminate facers to the outer panels of the foam core to form laminated foam pieces, wherein each of the laminate facers are comprised of different materials;   stacking the laminated foam pieces so that the laminate facers are not touching the same type of laminate facer material;   cutting the laminated foam pieces to the desired length and width; and   cutting hinges into the laminated foam pieces at appropriate locations in order for the laminated foam pieces to be configured into an insulating enclosure wherein edges of the foam core adjacent to the hinge are flush with the surface of the outer container.